Benchmark your hydraulic dredge performance

Transcription

1 White paper submitted by Charlie Johnson to Aggregates Manager. Posted as a web exclusive at: Benchmark your hydraulic dredge performance Contributed August 2, 2018 During your career in the aggregate industry, you ve likely encountered professionals who have offered their opinion, with absolute certainty, as to how much your dredge should be producing, even though they ve examined very little, if any, of your dredging operation. The fact is, excavating material from the earth and transporting material through a pipeline is not an opinion, but a science. Sizing up your dredge s level of performance in this process will take data and the application of engineering. The basics In order to best understand dredge performance, let s briefly examine how a hydraulic dredge works. A hydraulic dredge is made up of two completely separate and independent systems working together in harmony; a material excavation system and a material transport system. Most professionals who offer dredge productivity estimates to aggregate producers tend to only look at the transport system and ignore the excavation system completely. This may lead to confusion and frustration for the aggregate professional. The excavation system With respect to a typical basket-style dredge cutter head, some of the facets of the design that affect its production rate are: Horse power, Cutter diameter, Number of cutter blades, and RPM.

2 Of the parameters shown above, RPM affects the overall performance of the excavator due to its direct relationship to the breakout force produced by the excavator. Lowering the RPM increases the breakout force of the cutter, while raising the RPM decreases the breakout force. For this reason, dredge designers strike a balance between these two values by selecting an RPM that is just fast enough to result in a production rate that matches, or slightly exceeds, the transport capability of the dredge pump, while at the same time leaving a sufficient amount of breakout force for the material. The three most common problems with respect to the excavation system are; Insufficient excavator force to break out compacted materials, Improper aftermarket modifications made to screen material, and Improper excavator style selection. Analyzing the excavation capabilities of the dredge is the first step in determining your dredge s production ability. To illustrate how material compaction may affect your production rate, Table 1 shows a comparison of production rates between a firm material compaction (12 blow counts) and a very hard material compaction (50 blow counts) for four basic dredge sizes. Blow count information for a deposit is often included in a Standard Penetration Test (SPT) or boring log. These tests are often performed as part of the initial survey for a potential aggregate mine site. Sometimes, this data is contained in preliminary property exploratory records and may require some digging to find, but since establishing this compaction value is an important part of your dredge performance analysis, it s worth it. The transport system The dynamics of a dredge s transport system (dredge pump) are complex and have a myriad of conditions that can greatly affect the productivity of the dredge. In order to illustrate the effects caused by these conditions, we first need to establish a benchmark, under a particular set of conditions, for some various dredge sizes. The calculated production values below, expressed in short tons per hour, were calculated by analyzing the transport system only using the following common parameters: Well-graded very coarse sand, 30-foot dredging depth, 30-foot terminal discharge elevation, Hull-mounted dredge pump, and

3 1,000-foot discharge pipeline, 75 percent dredge efficiency (spuds). Now that we ve established reasonable production rates of the transport system, below is a list of variable parameters that can affect the production rate of a dredge s transport system. Dredging depth, Material gradation, Terminal discharge elevation, Discharge pipe length, and Discharge pipe diameter, Overall dredge efficiency. For production comparison purposes, we ll focus on the average production rate of each dredge size and apply some variations to the parameters listed above. Hull-mounted dredge pumps require atmospheric pressure to move slurry through the pump. Since a deeper dredging depth requires a longer suction pipe and this added friction is deducted from the atmospheric pressure available, less atmospheric pressure is available to move slurry through the pump. This results in a lower production rate. As shown in Table 3, the four dredge sizes experienced a reduction in the production rate ranging from of 72 to 118 short tons per hour.

4 One of the most common problems is using an improperly sized discharge pipeline. This causes the aggregate industry to lose millions in gross revenues annually. As you can see from Table 4, an improperly sized pipe would result in a reduction of production rate ranging from 20 to 181 short tons. Also, if we analyze the performance of the 16-inch dredge with the 40-inch diameter impeller, we would find that, when operating on the 14-inch SDR 17 HDPE discharge pipe, the transport system would have an output of 181 tons per hour less than when operating on 16-inch SDR 17 HDPE pipe. In addition, the dredge pump would operate at a 74.7-percent pump efficiency in 14-inch pipe compared to a percent pump efficiency when on 16-inch pipe. Material gradation Another variable in the transportability of material through a discharge pipeline is gradation. A material gradation has two indicators that are used to calculate the friction that will be experienced in a discharge pipeline. They are the D50 and D85 value. The D50 value indicates the size of sand particle that represents 50 percent of the mixture, meaning 50 percent of the sand particles are larger and 50 percent are smaller. The same principle applies to the D85 value, except 15 percent of the particles are larger and 85 percent are smaller. Determining the D85 value provides the slurry engineer with an indication as to the overall coarseness of the raw material mixture and is a necessary data point to properly calculate the amount of friction caused by the material in a discharge pipe. Sadly, these values are rarely gathered or used by most. 1,000-foot vs. 2,500-foot discharge distance Quite often, and more often than you might think, we find aggregate producers pumping material on excessively long discharge pipelines in order to avoid purchasing a booster pumping station that the discharge pipeline desperately needs. In the short view, it appears that the business is saving money, when in actuality, it s a very effective way to finance failure. The objective of the dredge operator is to maintain a flow of slurry to the plant at a particular or reasonable velocity. As the pipeline increases in length, so does the amount of friction in the pipeline, causing the operator to increase the speed of the pump to overcome the additional friction. The process of adding pipeline and increasing speed continues until the maximum pump speed is reached. If pipeline is added after the dredge pump has reached full speed, the added friction begins to slow the slurry flow and transport rate, and production begins to decrease. The transport production rate decreases for two reasons. Turbulence is what keeps material in suspension and is created by the slurry velocity in relation to the roughness of the pipe material. Now, let s assume for a moment that, at a sufficient velocity, the transport pipeline has the ability to suspend a

5 maximum density of 35 percent solids by weight. Because additional pipeline was added after the dredge pump s full speed was reached, the flow rate has decreased, causing a reduced level of turbulence. The slurry flow rate is now only capable of suspending a maximum density of only 30 percent solids by weight. So not only has the production decreased due to the lower flow rate, but the slurry is also less dense than before, further exacerbating the decrease in production rate. This explains why the production rate drops so quickly as pipeline is added once full pump speed is reached. In addition, because pipeline was added after the dredge pump s full speed was achieved, the dredge pump is operating at a lower pump efficiency. As slurry flow through the dredge pump decreased and the pump speed remained the same, recirculation of abrasive material within the dredge pump increased. Material that once passed through the pump quickly now makes several revolutions around the pump case before leaving the volute. This reduction in dredge pump efficiency increases the pump part wear rate the most expensive wear parts of a dredge. To illustrate the effect of excessively long discharge pipelines, Table 5 details the decrease in the production rate and dredge pump efficiency for the four dredge sizes. As you can see, the result is a decrease in aggregate gross revenues and a simultaneous increase in repair costs and downtime, making the addition of a booster pumping station a less expensive necessity. Conclusion Our industry is evolving and becoming leaner and greener each day. Today, we are more and more aware and sophisticated from environmental initiatives to data gathering and monitoring. A dredge is, for most, the primary mining machine, so the dredge analysis should play a primary role in this approach. While benchmarking a specific size dredge to a specific production rate is a desirable goal, there are far too many variables that affect its production rate to have a single benchmark. A step-by-step analytical approach is required to know if your dredge is truly performing to the best of its ability. Charlie Johnson is the director of domestic dredge sales for DSC Dredge, LLC.